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Check out new video of the Plasanator on

This Ebook is designed for Guys and Gals who like to create tools and machinery.

I hope my Ebook gives you hope that no matter how hard a project may seem, keep plugging away until you finish and you will succeed.

I spent 3 years putting this together and now finally all my hard work and research has paid off.

I studied diagrams from commercial venders, but to no luck. They tend to leave a lot out – on purpose - so it’s hard to reproduce their design. I’ve see different attempts at people making their own on You Tube and other sites, but what a death trap. Messy water resistors and wiring like a darn Christmas tree.

So I began reading books and articles on their workings and took my home schooled-knowledge of electronics to build my own plasma cutter. I was determined; failure was not an option.

I started by collecting parts from old microwaves, stoves, water heaters, air conditioners, car parts and more in the hopes of creating a low budget way to create a plasma cutter for myself. I mounted it all on a simple piece of scrap wood; well it’s scrap wood now. We, didn’t need that table anyway (shhhhhhh don’t tell the wife).

Then one day it all came together. I hit the power switch, placed the head to the metal, started the arc, felt the air kick and then a second hard kick (the current being drawn into play). Then BAM, it was slicing through quarter inch steel like a hot knife through butter.

How sweet it sounded! I felt the amazement of completing a project that I just couldn’t let go of.

So, take your time, enjoy and be safe.

The Plasaman

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JakubE1 month ago

Why do you put arc tip to the torch on outside and not to + work clamp?

Plasanator (author)  JakubE1 month ago

I have one side to tip and other is connected to clamp inside

en2oh1 month ago

any thoughts on modifying a stock DC inverter welder like a cheap Harbor freight to function as a plasma cutter?

Nice instructable

Plasanator (author)  en2oh1 month ago

If the voltages are the same as regular welder it wont work, need higher voltages.

If they are at least 300 coming out it will.

Plasanator (author) 1 month ago

No reason go for it.

The idea is to use what you can afford and find,

en2oh1 month ago

any reason not to use a simple furnace oil burner module for the arc start? I think it would be more reliable and cheaper

This is so helpful, Sir, thank you for sharing your hard earned knowledge. My buddy and I are in the collecting parts phase, and this is already very helpful. Thanks again!

PS: I'm sure I'll be back with questions at some point, hope you don't mind!
Plasanator (author)  Benjamin.M.Withrow1 month ago


JakubE2 months ago


please, have you some plans of Plasanator (5)? I need something with little more cutting power.

Plasanator (author)  JakubE1 month ago

im working on but soon.

JakubE JakubE2 months ago

Is it possible to use two 6kW heating elements with 230V?

Plasanator (author)  JakubE1 month ago

should work fine.

Plasanator (author)  JakubE1 month ago

Still working on them want them to be perfect for this will be my last version.

this is awesome, im a little hung on the ins n outs as of right now but i will research as you did , i reckon i will need a different circuit as we use a higher voltage in england. good work for pioneering for us all and sharing that :D

Plasanator (author)  ash.springer.91 month ago

what voltage do you use? if its 220or 240 it will work great.

bettina-sisr2 months ago

YOU ROCK! (Or cut )with style! This is great, gotta a extra one of you? Anyway thanks for this inspiration, I'm not smart enough to create this, but I love that other hard working people are!

Upaa273 months ago

Correct me if I am wrong, but wouldn't something like this work? T1-3 are microwave oven transformers. If we wind these for 200v each, the rectification should push the voltage to almost 300v to charge the caps. C2 dumps through T4 to ignite plasma and C1 can then discharge through the plasma. I would imagine with 3000uf, it should maintain continuos discharge with 15 amps even if only 60hz. I used 3 ac mains so that no breakers blow. The air flow and fan could be easily incorporated into the schematic I just didn't find any symbols for them.

What do you guys think?

Upaa27 Upaa273 months ago

Sorry I mean to say the total voltage output is 200v from the transformers not 200v each. I'm really tired right now :O

this pic should've been fist page not third or forth in line.

After all of this man's hard work, that's what you get out of this? Please, for your own sake, don't try building this lmao
great job,, where can i salvage the high voltage bridge rectifier. i can't seem to find anything that uses one that can handle this much voltage,,other than just buying a new one, thx
Plasanator (author)  dthompson326 months ago

eBay has them for about 16 bucks.

Plasanator (author)  dthompson321 year ago
(removed by author or community request)
Plasanator (author)  Plasanator6 months ago


This is link on eBay where I bought some rectifiers.

These work great and will handle all your power needs.


Great project. I am in the works of constructing my own working from your design. I have two questions. Is the isolation transformer necessary? Also, what are you using for your compressed air source? Just an air compressor? Thanks in advance!

Plasanator (author)  experimenter4life6 months ago
I don't use one since all is shut down by gun trigger never had a problem or safety issue.
I just use a regular air compressor bigger the better if you have a lot of cutting to do air last longer and I use a 50 gallon hot water tank made in to an air tank secondary.

Great thanks. Sorry I have one more question I forgot to ask. When you turn the unit on, does it blow the breaker while the capacitors are charging up? Seems like they would pull a looot of current to charge being so big and all. If so how do you work around that problem?

Plasanator (author)  experimenter4life6 months ago

I have never had that problem.

Make sure you have a 30 amp breaker for 120 and at least a 50 amp for 220 use.

Also make sure the 120 power that comes out of your relays is not connected to the other side of ac connection.

Follow the yellow that goes to the two joined relays and comes out blue to high voltage set up and to air solenoid .

PetrieJ6 months ago

Is is possible to make a 1A plasma cutter? I need to cut very thin pieces of 304, but because of the geometry and composition of the parts I am currently stuck chemically etching the material away.

Plasanator (author)  PetrieJ6 months ago
I wouldn't think so and plasma cutting would leave spray all over pcb board.
I recommend using A laser or Drexel tool.
V4V6 months ago

i cant understand why you connect the caps at this strange way. after the bridge you have a plus and a minus full rectified source. so the caps should take this dc voltage.
why do you connect the caps back to the AC line?

Plasanator (author)  V4V6 months ago
It forms a voltage doubler circuit.
rodalino6 months ago

Can this cut aluminum and stainless sheets?

Plasanator (author)  rodalino6 months ago
Yes it can and does very well.
swampfox4407 months ago

What is the water heater element for ? Don't see it anywhere in these pictures.

Plasanator (author) 10 months ago

Hey all just solder a wire to the hv coil instead of zip tying it and cover solder with silicone of any kind.

wkdavistx1 year ago
If i am putting 240v to the contactor does that mean I'm putting 240v to the air solenoid? I am also reading 650v on the dc side of the rectifier. I am replacing both of these parts (fried the 110v solenoid).
Thank you.
Plasanator (author)  wkdavistx10 months ago

No then you have it hooked up wrong.

The air solenoid goes before the contactor on the input side through a relay.

pgladek2 years ago
Sorry, I also forgot to might be hard to find a ford / chevy ignition coil out here, so is there anything specific I should look for when I pick one out, or any minimum specs needed? Also, is there any purpose to mounting the stud on the ignition coil, other than as a place to attach the connections? And what does the water heater element specifically do?

its a dump load. instead of a large amount of copper or aluminum. he went with that tho it needs a bigger heat sink tho.

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